Process of making water gas



May 31, 1949. Q. R. STERE 2,471,79

PROCESS oF MAKING WATER GAS Filed Sept. 26, 1945 6 Sheets-Sheet l ATTORN EY May 31, 1949. G. R. STEERE .2,471,791

PROCESS OF MAKING WATER GAS Filed Sept. 26, 1945 6 Sheets-Sheet 2 llllllll A ISINIMSINIJISISNN SIMSISISISISISISL'ISR INVENTQR eofjge Seefe BY l ATTORNEY May 3l,` 1949. G. R. STEER.; 2,4%791 PROCESS OF MAKING WATER GAS Filed Sept. 26, 1945 6 Sheets-Sheet 3 /l/NVENTOR George@ Sfeer@ BY ATTORNEY- May 31, 1949. G. R.S"TEERE 2,471,791

PROCESS `OF MAKING'WATER GAS Filed Sept. 26, 1945 6 Sheets-Sheet 4 INVENTOR ATTORN EY May 3-1, 1949. L G. R. srEE-RE 2,471,791

PROCESS 0F MAKING WATER GAS Filed sept. 2s, 1945 v e sheets-sheet 5 INVENTOR Geafjge Sfeer@ ATTORNEY G. R, TEERE PRocEss or'mxme WATER GAS May`3l, 1949.

Filed Sept. 26, 1945 6 Sheets-Sheet 6 INVENTOR m ,my R MM/Mm @A Patented May 31, 1949 PROCESS F MAKING WATER GAS George R. Stoere, Ipswich, Mass. Application vSeptember'hii, 1945, Serial No. 618,670

This invention relates to the manufacture of water gas and more particularly to a novel process for making carbureted water gas.

Carbureted water gas processes are commonly carried out in a backrun Water gas set consisting of a generator, carburetor and superheater located in separate and detached shells connected in series. The generator and carburetor are of substantially the same size and the top of the generator communicates with the top of the carburetor. The superheater is substantially higher than the carburetor and has its base communicating with the base of the carburetor. The top of the superheater is connected with a wash-box into which leads the backrun line from the generator. Oil is admitted to the carburetor at the top thereof in a direction cocurrent withthe flow of water gas therethrough.

In such backrun equipment and in the conventional up and down run water gas sets which have been used for a great number of years prior to the development of the backrun, the air for blastingthe fuel bed is introduced at the base of the A generator and passed upwardly through the fuel bed, the resulting blast gases and the water gas A during the make runs flowing downwardly through the carburetor and upwardly through the superheater. I

In the recently developed Reverse flow water gas set `a generator, carburetor and superheater, located in separate and detached shellsare connected in series with the top of the generator communicating with the base of the carburetor,

and the'top of the carburetor communicating with thetop of the superheater so that llow takes place vup through the carburetor and down through the superheater, just the reverse of the direction of flow through these chambers in the conventional carbureted water gas equipment hereinabove described. In the operation of such Reverse ilow water gas sets air for blasting is introduced at the base of the generator and flowsupwardly through the fuel bed therein, the direction of flow of both the air and the steam through the fuel bed in the Reverse ow water gas process being the same asin the prior backrun water gas operations. i

Since the air for blasting is introduced in the base portion `of the fuel bed and flows upwardly therethrough the hottest portion Vof the fuel `bed is at the base thereof, the temperature of the fuel beddecreasing in a direction towards the top of the bed. h To protect the grates against these high temperatures it is the practice to operate with a bed of ash on the grates. This mode of operaat the bottom of the fuel bed for protecting the I grates and a temperature gradient through the fuel bedsuch that the temperature increases towards the base portion of the fuel bed which base portion is at the highest temperature, has been found to result in the formation of-large clinker masses particularly in the lower part of the fuel bed. Frequent clinken'ng operations are therefor necessary to effect the removal of such masses to maintain the fuel bed in a reasonably efficient .condition for carrying out the water gas reaction. Such clinkering not only involves arduous labor but reduces the capacity of the set and the eciency of the process.

It is an object of this invention to provide a water gas making' process particularlya carbureted water gas making process in which the formation of large clinker masses in the fuel bed is avoided; and the` fuel after substantially `com-- plete gasicationthereof is converted to ash vor small clinker particles which are substantially continuously removed from the fuel bed.

Another object of the invention is to provide a carbureted Water gas making process in which during the blasting step the blast gases ow downwardly through the superheater resulting in uniform heating of the checkerbrick therein, which uniformly heated checkerbrick are utilized in xing the carbureted water gas made during a subsequent make step and are also utilized to. superheat steam during another make step, such superheater are carburetor units being associated With a generator so that ilow of backrun steam takes place up through the fuel bed in the generator and in the other make step of the cycle of steps steam is passed downwardly through the fuel bed in the generator. In other words it is an object of this invention to provide a carbureted water gas process which is an improvement on the Reverse flow Water gas operations in that a complete reversal of ow is accomplished throughout the entire set, i. e., not-only is the direction of flow through the carburetor and superheater units reversed but also through the generator unit of the set.

Another object of the invention is to provide an improved process of making gas in which the backrun steam after passage through the active re zone of the fuel bed flows through the portion of the fuel bed containing relatively fresh fuel in an uncarbonized condition the Water gas remov- A `ing volatiles from the fresh fuel and the thus enriched Water gas is withdrawn from the set without being subjected to high temperatures which would cause over-cracking of the volatiles.

Still another object of the invention is to provide a process for making carbureted water gas which involves the more emcient utilization of the heat generated to produce gas as compared v with known water gas making processes. An-v buretedv water gas set in which the prccess ofl heat, regenerator chambers, if desired, may be combined in one and the same shell. An off-take tor chamber and thence up through the fuel bed the resultant water gas being withdrawn directly from the generator and steam also passed during .another step of the cycle of steps down through the fuel bed. When making carbureted water gas the water gas produced in the last mentioned step is introduced into the heat refV generator chamber which functions as a carburetor and the water gas carbureted by the addition of oil thereto.

Operating in this manner the air or other oxygen containing gas used in blasting the fuel bed first' comes in contact with the portion of the fuel bed where the percentage of ash is lowest andthe air or other oxygen containing gas is dispersed throughout the carbon content of the fuel bed. The oxygen containing gas reacts with the carbonite form carbon dioxide. This reaction being an exothermic one causes the -portion of the fuelbed contiguous to the vpoint where the oxygen containing gas is introduced thereinto to become highly heated; this portion, of the fuel bed is the portion at thehighest temperature. .As the blast gases formed, pass down through the fuel bed, the fuel bed is heated,

reaction takes place to form carbon monoxide.

which reaction is endothermic ypreventing excessively high temperatures in the lower portion of leads from the heat regenerator, e. g., the superheater to a wash-box or seal and an off-take, separate from and independent of the connection between the generator andheat regenerator leads from the; top of the generator to a Washbox or seal which may be the same wash-box into which the off-take from the superheater leads. The interior of the heat regenerators may be Ibuilt up with checkerbrick dening tortuous iiues for thek passagevof gas as is well known in this art, or the heat regenerator functioning-as .the carburetor may be devoid of Icheckers or other heat absorbing material.

In a preferred embodiment of the invention the generator and superheater may be of substantially the same height, say approximately 2a feet from the ground level, :and the carburetor approximately one-half the height of these units. The generator is provided with a bustle pipe having a series of ports extending through the generator walls at a point approximately mid-way between the topand the bottom of the generator for the admission to the fuel bed of air during the lblasting step and steam during the make run. The fuel bed may extend well above these ports, the portion of the fuel bed between the ports andthe bottom of the generator constituting the hot and active portion of the fuel bed for the production of water gas. A second bustle pipe is preferably provided for introducing tar or other hydrocarbon material into the side walls ofthe top of the active portions of the fuel bed. At the base of the generator athin layer of ash from the consumed fuel occurs. The fuel bed krests on revolving .crusher rolls or bars which function to effect continuous removal of ash from f the fuel bed.

In carrying out the process of this invention air or other oxygen containing gas is introduced burned in the heat regenerator chamber communicating with the generator to heat this chamber, steam is passed through this heat regenerathe fuel bed. Thus the temperature of the fuel bed gradually decreases from the point where the oxygen containing gas is introduced in a direction towards the base of the fuel bed, the temperature at the base of the fuel bed .being below the point at which substantial fusion of the ash constituents of the fuel bed takes place to form large clinker masses. The only portion of the fuel bed containing an amount of ash sufficient to cause formation of large clinker masses is the base portion of the fuel bed at which portion the temperature is below the fusing point of the Vash so that large clinker masses cannot form.

In operation the ash is removed substantially as rapidly as it is produced resulting in a fuel bed which contains a gradually decreasing amount of ash in a direction towards the .top of the fuel bed, there being little ashv in the top portion of the fuel bed-where the temperature may be above the fusing point of the ash.

In the operation of the preferred embodiment of the invention involving the use of a set comprising a generator, carburetorand superheater connected in series, blast gases are always passed downwardlyl through the fuel bed, flow up through the carburetor and down through the superheater efcientiy heating the checkerbrick in the superpreceding step and preferably also through a superimposed portion of the fuel bed containing fresh or green coal, when coal is used as the generator fuel, removing volatiles from the coal. The resultant mixture of water gas containing volatiles is withdrawn from the generator and `passed directly to the wash-box. It will be noted that this mixture does not pass through the hot fuel bed thereby avoiding over-cracking of the .volatiles resulting in an enrichment of the water gas with consequent saving in the amount of oil which need be added for this purpose.

Preferably in the reverse run from 60% to 95% gas thus produced is passed up through the carburetor where it is enriched by oil introduced into the top portion of the carburetor in a direction counter-current to the ow of water gas therethrough and the resultant carbureted water gas is fixed by flow downwardly through the superheater. The carbureted'water gas thus produced and the water gas formed during the backrun with or without enrichment by the volatiles removed from the coal are mixed in a suitable holder.

It will be noted in the process hereinabove de- 1 scribed complete reversal of iiow throughout the entire set is accomplished, i. e., not only is the direction of flow through the carburetor and superheater units reversed during the backrun as compared with the direction of flow during the blast, but also the flow through the generator is reversed. Moreover as compared with known water gas making processes the process hereinabove described more efficiently utilizes theheat generated to produce gas. This may be chiey attributed to' the reverse run in which as much as from 60% to 95% of the total steam is employed, which steam removes heat from the superheater and carburetor units and restores this haat to the fuel bed in the generator permitting its eifective use in the, Water `gas making reaction. Furthermore sin-ce in the preferred process of this invention the carbureted water gasmaking step involving the ow of steam through the fuel bed does not immediately follow the blasting step, uniform production of gas throughout the make steps results. In prior processes in which the `carbureting `Water gas step followed the blasting step, since the steam `employed in thisstep was introduced in the fuel bed when it was at its maximum temperature a maximum amount of water gas was generated which amount of gas was augmented by the oil gas produced in the carburetor, resulting in peak production of gas during the initial portion of the uprun step. In the preferred process embodying my invention a reverse or backrun follows the blasting step and when the temperature of the fuel bed has been reduced from its maximum point as a result of the backrun a run is employed involving the flow of steam through the fuel bed and the carburetion of the water gas thus produced resulting in more uniform generation of gas throughout the make steps.

In the operation of a set in which the generator is of standard height, i. e., substantially the same as the carburetor, the air for the blasting step and the steam during the make run 'in which the steam is passed down through the h invention is not limited to the brick lining of the generator and the fusion thereof to form clinker masses.

In the accompanying drawings forming a part of this specification there is shown for purpose of exempliflcation preferred embodiments of carbureted water gas'sets for practicing this invention. It will be understood, however, that the the setsillustrated. In the drawings:

Figure 1 is a vertical section partly in elevation of a carbureted water gas set in which the invention may be carried out;

Figure 2 is a vertical section partly inelevation of a modified form of a carbureted water gas set in which this invention may be practiced;

Figure 3 is a vertical section partly in elevation of 'still another modified form` of a carbureted water gas set in which this invention may be carried out;

Figure4 is a planview set of Figure 3;

Figure 5 is a vertical section partly in elevation partly in section of the -of a. two shell carbureted water gas set in which this invention may be practiced; and

Figure 61s a vertical section partly in elevation of a modified formof a two shell carbureted water gas set in which this invention may be practiced. Referring to Figure l of the drawings reference characters III, II and I2 indicate the generator,

carburetor and superheater, respectively, located in' separate and detached shells and connected in series with the bottom of the generator communieating with the bottom of the carburetor through passageway I3 and the top of the carburetor II communicating with the top of the superheater through the refractory lined passageway I4. A stack I5 leads from the base of the superheater and is providedA at its top with a stack valve I6. The generator is provided with a charging device which may be of any well known type and is indicated by the reference character II. A backrun pipe I8 leads from the top of the generator I0 to a three way valve housing I9, which three way Valve'may be of the standard type now blasting step and also during the reverse steam commonly used to control flow through backrun water gas sets. This housing I9 is connected by a pipe 20 with the stack I5 and by pipe 2I with a wash-box 22 of any well known type. Gas offtake 23 leads from the wash-box to the usual by-product recovery equipment.

As customary the superheater is provided with checkerbrick 24 supported on piers 25 and is thus a heat regenerator chamber as will appear from the description hereinafter. The carburetor II is preferably devoid of checkers although if desired two or more layers of checkerbrick may be disposed near the base portion thereof. This carburetor is provided with a retractible oil spray 26 near the top thereof for introducing oil which may be heavy oil such as Bunker C oil into the upwardly flowing stream of water gas. The oil spray 26 may be retracted from the carburetor by means of a-hydraulic cylinder 21 during the run, if desired; when it is desired to add oil t0 the reverse steam and to the make water gas the oil spray ismoved into the carburetor in the position indicatedin Figure 1 of the drawings by the hydraulic cylinder 2'I as will be understood by those skilled in the art.

The generator I0 in the embodiment of the invention shown in Figure 1 is of the same height as the superheater I2, whereas the carburetor is of a height approximately one-half that of the generator and superheater. Both the generator andcarburetor rest on a ysupporting foundation 28,'the interior walls 2.9'thereof sloping towards eachother to form a rectangular ash pit 30. An ash removing device 3| which may be in the form of crusher'barsor rollers adapted to be rotated bylany suitable drivir'ig mechanism (not shown) is disposed inl the'l ash pit 30 at the base of the inclined walls 29. This ash removingfdevice supportsrva, bed Aof fuel in thegener'ator, as shown in Figure v l of the` drawings, a' portion of this'fuel bed extending'into the base' portion of the carburetor. y, The ash removing device it will be noted Vlsd'isposed well below the bottom'of wall 32 defining the upper portionof the connection I3 betweenthe generator and carburetorso that the Aash'rlernoving ,device is disposedy out of the the generator to the carburetor. l

A bustle pipe 33 encirc1es the generator andi is path cfrnovementof Ithe hot gas flowing from' provided with a series of ports 34 extending through the walls of the generator. `This bustle pipe it will be noted lies in a plane at an acute angle to the longitudinal axis of the generator so that the ports 34 lie in alike plane. Hence the distance from each of the ports to the passageway I3 communicably connecting the generator with the carburetor is substantiallyA the same as willvbe evident from an inspection of Figure 1. Thus-air during the blastingv cycle and steam during the make cycle introduced through ythese ports flows through substantially the same extent of fuel bed. The bustle pipe 33 communicates with a main 35 for supplying air under pressure generator and ycarburetor having a base connection such as shown Ain Figure 1.

In operation the generator I0 is charged with matic charging machine I'l.v Preferably, but not necessarily, the dimensions of the generator are such that the' space above the ports 34`and below the offtake I8 in which the fresh fuel accumulates in the generator is adequate to contain enough fuel to operate the machine fory about '5 lhours the fuel in this space being replenished thereto. A valve 36 controls the flow of air to i the bustle pipe. A second bustle pipe 33' providedwith a series of ports 34' extending through the walls of the generator, may be provided to supply tar such as water gas tar, or coal tar, or other hydrocarbon material to the sides of the fuel bed. This bustle pipe is disposed just below the bustle pipe 33 and is thus positioned at the top of the active portion of the fuel bed. The ports 34 are positioned at spaced intervals completely around'the circumferential surface of the fuel bed and preferably, as in the case of the ports 34, lie in a plane at an acute angle to the longitudinal axis of the' generator so that the distance from eachof the portsvto the passageway I3 is substantially the same. -A steam line 31 provided with a valve 38V supplies steam to the bustle pipe 33 during the make run. i A steam line 39 leads into the top portion of the stack for supplying steam to the set for the reverse run.

The ash pit 30 yis disposedvin a. sump 40 in a,V

concrete foundation for the set. Liquidsuch as water is maintained in the sumpto provide a liquid seal for the bottom ofthe generator "and 'the communicating carbureton'preventing escape of from time to time as needed by the automatic charging machine to maintain the level of fuel within the'generator substantially constant.

The fuel bed is first blastedby passing air or other oxygen containing gas through bustle pipe 33 and ports 34 into the generator downwardly" bed. The temperature of the fuel bed thus varies from the highest temperature at the point of introduction of the air into the fuel bed to a lower: temperature at the base portion of 'the'fuel bed, :.1.

the blasting operation being carried out so as `to avoid creation of a temperature in the portion of the fuel bed indicated by the legend Cooler zone which is above the fusing point of the ash in this zone. Thus, as shown in Figure 1, at the end of the blasting cycle the fuel bed consists of a 'zone constituted of green coal which zone is disposed above the ports 34, a lower zone constituting the hottest zone in the fuel bed, a still lower zone designated as the cooler zone and a zone indicated by the legend "Ash" contiguous to the ash removing device 3|. It will be noted I the direction of the blast is always downwardly through the fuel bed. I

To sup-port combustion of the blast gases thus produced, secondary air is admitted to the base of the carburetor through an vinlet 43. The resultant blast gases burn as they flow up through the carburetor and down through the superheater -and leave the set through the stack I5, stack valve I6 being open and three-way valve I9 positioned so that flow through the backrun line I8 is prevented.

Upon terminationof the blasting eyclewhich v'may be of from50 to 100 seconds duration, a regases from theseunits. An endless conveyor 4I receives ash from the pit 30 substantially continuously discharged by the ash removing device 3| and moves this ash through the liquid seal to a discharge chute 42 from which the ash'may be discharged into a dump truck or other device for effecting disposal thereof. Thus the ash may be discharged continuously without interfering with the gas making operation.

Instead of the type of.v generator shown in Figure 1, of a height approximately equal to that of 'verse run follows. Before the steam is introduced through,l inlet 39, stack valve I6 is closed, the three-,way valve I9 being moved to close Aconnection 20 Aandplace the backrun line I8 in communication with the wash-box. Steam is introlduced throughv inlet 39 `:flows down through the stack I5 up through the superheater and'down through thecarburetcr, the steam thus removing heat yfrom the stack, superheater and carbu- Aretor and restoring this heat to the'fuel bed. The

water gas and coal volatilesdoes not pass through the hot portion of the fuel bed, nor is it otherwise subjected to high temperatures which would cause over-cracking of the volatiles with consequent carbon formation and reduction in the quality of gas produced. 'I'his reverse run may be of from 100 to 180 seconds duration, and in this reverse run from 60% to 95% of the total make steam employed in each cycle of steps is passed through the stack, superheater and carburetor and into and through the fuel bed.

A make run follows this reverse run and for this purpose the three-way valve I9 is operated to open the port connecting the stack I with the wash-box and to close the backrun pipe I8. Steam is introduced by pipe 31 through ports 34 into the top of the hottest zone of the fuel bed flows down through the fuel bed the resultant water gas passing up through the carburetor countercurrent to the oil introduced by spray 26. This oil may be heavy oil. The carbonaceous deposits formed upon the decomposition of the oil, it will be noted, settle onto the portion oi.' theffuel bedin the base of the carburetor andr is consumed in the subsequent blast and make runs. The carbureted Water gas thus produced'flows down through the superheater where it is fixed and then passes through the stack into the washbox. This run may be of 60 to 120 seconds duration. From 5% to 40% of the total make steam employed in each cycle of steps is passed through the fuel bed during this make step.

The above three steps represent the main steps of the cycle of steps, which cycle of steps is repeated, preferably in the order mentioned, throughout theoperation of the set. As the set is operated, ash is continuously withdrawn by conveyor 4I, coal added to the green coal zone is continuously gasifed, i. e., volatiles are removed by the backrun water gas which volatiles enrich the make gas resulting in' a reduction of carburetor and the resultant carbureted water gas being fixed as it flows up through the superheater I2'. 'I'he set of Figure 2 it will be noted differs from Figure 1 in that it does not involve a stack leading from the superheater. It has a stack valve 41 positioned on the top of the superheater.

The cycle of steps carried out in the set of Figure 2 is preferably the same as that hereinabove described in connection with the operation of the set of Figure 1; it will be understood, however, that the direction of flow through the superheater and carburetor during each step is the opposite of that involved in the set of Figure 1. Thus during the blast blast gases flow down through the carburetor and up through the superheater. During the reverse run steam flows down through the superheater up through the carburetor, oil being added to the steam when it is desired to reform, and the steam passing up through the fuel bed, the gas thus produced removing volatiles from the green coal zone of the oil requirements, and in the further progress of the coal throughthe fuel bed complete'gasiflcation thereof is effected Without the formation of large clinker masses, any small clinker particles being crushed by the ash removing device 3| and removed with the ash from the fuelbed.

Thus my invention provides a continuous gasification process in which coal is completely gasified and the heat generated is efficiently utilized to make combustible gas. By having the reverse steam "top immediately follow the blast the heat generated is most efficiently used and ex-` cessive peak formation of gases avoided vas hereinabove pointed out. 1

In the modification of Figure 2 like reference numerals have been used to indicate like parts. This modification differs from that of FigureA 1 chiefly in that it involves the use of a reverse flow generator embodying my invention with4 a carburetor and superheater in which the flow of water gas takes place down through the carburetor and up through the superheater and flow of reversesteam takes place down through the superheater and up through the carburetor. In the set of Figure 2 generator I0 is connected to carburetor II by a refractory lined passageway 44 which leads from the base ofthe generator into the top of the carburetor. Secondary air inlet 45 is provided in the base of this connection to supply secondary air to support combustion ofthe blast gases. An oil inlet 4B is disposed at the top of the carburetor to supply oil which may be heavy oil to the carburetor during flow of watergas therethrough, the oil and gas flowing cocurrently down throughthe the fuel bed, the resulting fuel gas passing through pipe I8 to wash-box 22. Upon completion of this reverse run steam is passed through the ports 34 down through thefuel bed, the resultant water gas flowing through passageway 44 to the carburetor where it is carbureted by oil introduced through spray 46, the carbureted Water gas passing from the base of the carburetor up through the superheater and then flowing through three-way valve I9 into the wash-box 22.

In the interests ofclarity the conveyor for continuously removing ash and the associated ash pit and liquid seal have not been shown in Figures 2 and 6. Theconstruction of these parts is the same as that hereinabove described in connection with the showing thereof in Figure 1. The modification of Figures 3 and 4 involves a generator of standard height, i. e., substantially the same as that of the carburetor and substantially less than that of the superheater. These two figures illustrate an embodiment of my invention in a reverse flow water gas set, which embodiment can readily be incorporated in existing reverse flow water gas sets with minimum changes in such sets. Thus the chief changes required are to modify the connections between the generator and carburetor and the generator and wash-box so that the backrun line, instead of leading from the bottom of the generator as is the practice in existing sets, leads from the top of the generator to the three-way valve communicating `with the wash-box and a connection is provided betwen the bottom of the generator and the bottom of the carburetor.

In Figures` 3 and 4 the generator, carburetor and superheater are identified by reference characters a, b and c, respectively. The conduit d connects the base of the generator with the base of the carburetor b, and conduit e leads from the top of the carburetor into the top of the superheater. The parts of the set of Figures 3 and 4 which are the same as those of the set of Figure 1 have been given like reference characters and it is believed no useful purpose would l 1 l be supplied to the generator to flow downwardly therethrough through a pipe k leading into the backrun line f. As customary the backrun line f may be provided with a safety valve m.

The bottom of the generator is formed with an annular space n with which communicates the connection d between the generator and the carburetor. As shown in Figure 1 this annular space n is built into the brick lining o for the generator. If desired, however, this annular space may be ,formed on the exterior of the generator shell so that the interior of the generator is of uniform diameter throughout its height rather than having a'portion -of smaller diameter near its base and a larger diameter portion at its top, as shown in Figure 3. The base portion of the annular channel or space n communicates through a series of ports p, six in the embodiment shown in Figures 3 and 4, with the portion of the fuel bed directly above the ash removing device 3|.

With the construction shown; during the reverse run, steam ows through the connecting passageway d of relatively large cross sectional area into the annular space n which is of relatively large volumetric capacit-y thereby tending to reduce the velocity of steam now and then flows through the series of ports p, the combined exit area of which is relatively large minimizing turbulent now and resulting in relatively smooth flow of the steam up through the fuel bed with consequent improved reaction between the steam and the carbon content of the fuel to produce water gas.

The top of the generator is provided with a bustle pipe q provided with a series of ports extending through the generator walls. The bustle pipe q and ports 'r in general corresponding to bustle pipe 33' and ports 34 in Figure 1, except that in the modication of Figure 3 the pipe and ports lie in a horizontal plane at` right angles to the longitudinal axis of the generator.

The cycle vof steps carried out in the set of Figures 3 and 4 is preferably the same as that hereinabove described in connection with the operation of the set of Figure 1. Thus during the blasting step, air is introduced into the top of the generator above the fuel bed, flows downwardly therethrough, the resultant blast gases owing through the ports p into the annular space n through the connecting passageway d into the base of the carburetorwhere they are mixed with secondary air introduced` through pipe the blast gases burning as they flow up through thecarbureto'r', v.down through the superheater and up through the 'stack I5.` During the reverse runy nsteam introduced through pipe 39 flows down through the stack, up through the superheater, down through the carburetor, through the passageway d', annular space n, ports p,.into the base'of the generator upwardly therethrough the resltant'water gasowing through the backrun pipe finto the three-way valve housing I9 and' thence vto the wash-:box Upon completion of this# reverse run, steam ispassedvthrough pipe. k into the backrun pipe "f; flowsv down through vits heater. The carbureted water gas flows through the stack l5 into the three-way valve I9 and thence into the wash-box 22.

In the modification of Figure 5 a generator 46 of conventional height, i. e.. approximately onehalf the height of the generators of Figures 1 and 2 is employed. The base of this generator communicates through the large open passageway 49 with the base of the carburetor 50. A superheater 5I is superimposed on the carburetor 50 and this superheater is provided with a stack valve 52.

` As in the modification of Figure 1 the generator and carburetorrest on a supporting foundation 53 having inwardly sloping walls 54, the base of which form a rectangular opening 55. -Ash removing device 3l is positioned in this opening 55 out of the path of hot gases flowing from the generator to the carburetor. Tl

At the base of carburetor 50 is positioned a secondary air inlet 56. An ignition dome of refractory material having a central opening is disposed just above the secondary air inlet for the purpose of insuring ignition of the mixture of air and blast gases as they f'low up through the carburetor. In the modification shown in Figure 5, except for this ignition dome, the carburetor is devoid of checkerbrick. If desired, however, two or more layers of checkerbrick may be disposed above the ignition dome. An oil spray 58 which may be of a retractible type as described in connection with Figure 1 is disposed at the top of the carburetor unit 50.

The base of the superheater is in open communication with the top of the carburetor, both of these unitsY being located in one and the same shell. Checkerbrick 59 fills the superheater, these. checkers resting on supporting arches 60.

A linek 6I leads from the top of the superheater to a three-way valve housing 62. This line 6| is provided with a steam inlet 63 for supply- 'lng steam to the superheater for the reverse run.

A line 64 leads from the top of the generator to the valve housing 62. This valve housing is connected with the wash-box 22 by a line 65.

An air line 66 having a valve 61 therein communicates with the topof the generator. Steam is supplied to the top of the generator throughsteam inlet 68.l

Disposed near the top of the fuel bed inthe generator I8 is a bustle pipe 69 which encircles the generator and'is provided with a'series of ports 'I0 extending throughy the generator wall. Bustle pipe 69 is provided with hydrocarbon material vsuch as tar or heavy oil through valve. controlled pipe 1|'.

The tar or heavy oil rintroduced through the port 10 flows down along the sides ofv the generator` forming masses of carbon contiguous to the side walls which .being of greaterdensity thanthe remainder of the fuel bed impede andprevent the ow of gas along the'fuel'fbed injthe generator, tar, which may be water gas tarA or coal tar,y being simultaneouslyv the side walls, thus preventing channelling of gas along thel side walls and causing flow cf gas during both the up and back runs through the fuel bed to t'ake place chiefly away from the side Wallsthrough the active main portion of the fuel bedyresulting'in more eiilcient steam carbon reaction to vproduce water gas and prevent adhesion of ash to the brick lining of thegenerator and the fusion thereof to form clinker masses along the side walls of the fuel bed. The tar or other hydrocarbon material is introduced-durcarbuted with ou and the carhureted water gasfilxed as it rowsdow'n lthrough the `Supering the step involving the flow of steam down through the fuel bed. v

In the operation of the set of Figure the fuel bed is always blasted downwardly by the introduction of air through pipe 66, the resultant blast gases being burned as they flow up through the carburetor and superheater, the air necessary to support combustion being supplied through secondary air inlet 56 and ignition of the mixture being insured by the ignition dome 51. The blast gases leave the superheater through the stack valve 52. 'Thereafter this stack valve is closed. steam is admitted through steam inlet 63 flows down through the superheater and carburetor into and up through the fuel bed in the generator, the resultant gas being withdrawn through pipe 64 passing through three-way valve housing 62 thence through the pipes 65 into the wash-'box 22. Upon completion of thisstep the three-way valve is moved to close the backrun line 54 and place 1in 6l' in communication with the wash-box. Steam is then admitted through inlet 58 passed down through the fuel bed and tar or other hydrocarbon material is added to the fuel bed to form carbon masses along the side walls as hereinabove explained. The flow of the steam through the central main active portlon is insured by the formation of carbon masses along the side walls as hereinabove described. The resultant water gas flows uputhrough the carburetor where it is carbureted by oil'added through the line 58 and the carbureted water gas flowing up through the superheater into the three-way valve housing 62 and thence into the wash-box 22.

The duration of the cycles and the amount of steam employed during the reverse run and the make run involving the 'flow of steam down through the fuel bed preferably is the same as in the cycle of -steps hereinabove described in connection with the operation of the apparatus of Figure 1. l

In the operation of the set of Figure 5 it will be noted the fuel bed is blasted always downwardly thereby resulting in the formation of a fuel bed having its maximum temperature at the top and its lowest temperatures at the bottom, the ternperature of the base being below the point at which fusion of ash takes place. Moreover the ash content of the fuel bed increases from top to `bottom of the fuel bed and the ash being contlnously removed as formed by the ash removing device 4| as described in connection with the operation of the apparatus of Figure 1.

The set of Figure 6 differs from that of Figure 5 chiefly in that a generator the same as that involved in the modification of Figures 1 and 2 is employed; otherwise the set of Figure 6 is substantially the same as that of Figure 5, i. e., it involves a superheater superimposedon the carburetor both units being located in one and the same shell the base of the carburetor communieating with the base of the generator. The parts of the apparatus of Figure 6 corresponding to those of Figure 1 have been given the same referencecharacters. It is believed the structure and operation of the set of. Figure A6 will be evident to those skilled in the art from the above description may be carried out when desired, say afterI the blast and before the make run to prevent fomatlon of explosive gas mixtures within the se From the above description of my invention it will be noted that formation of large clinker masses does not take place in the fuel bed; and ash and small clinker particles are removed continuously without interrupting the gas making operations; hence it is not necessary to shut down the set periodically for removing clinkers and cleaning and repairing the generator side walls, as is the case in carbureted water gas processes heretofore practiced. Accordingly my invention savtes labor and generator lining maintenance cos The use of a reverse run involving the flow of a major portion of the steam through the fuel bed with aconsequent increased recovery of heat saves fuel, and makes it possible to use a shorter blast run thereby increasing the capacity of the set to produce make gas. Furthermore less steam is required per thousand cubic feet of water gas produced since the major portion of the steam, preferably from 60% to 95% of the total make steam, passes up through the fuel bed in which the temperature gradually increases from bottom to top of the fuel bed resulting in a very efficient utilization of the steam in the water gas reaction.

Formation of excessive peak production of gas is avoided since in operating in accordance with my invention the blue gas or water gas is carbureted during the run following the reverse steam run at which point in the cycle, relatively low blue gas production takes place resulting in more uniform gas production throughout both the reverse run and the run in which steam passes down through the fuel bed. Furthermore due to the employment of the reverse run preceding the carbureting water gas run the superheater is cooled to bring its temperature to a point below that at the point where the oil is admitted to the carburetor, thus providing a proper heat gradient from a high at the point of oil admission to a low at the outlet from the superheater; this results in conservation of oil used for carbureting purposes.

Operating in accordance with my invention with a large body of green coal above the` point of introduction of the oxygen containing gas in the blasting step result-s in substantially smokeless operation. In my process it will be noted the air for blasting always flows downwardly through the fuel bed, and hence passes through a substantial depth of hot fuel resulting in combustion of any volatile material removed from the fresh fuel. Hence little or no volatiles are left in the blast gases discharged into the atmosphere 4through the stackwith consequent elimination of smoke. The feature of always blasting the fuel bed downwardly has the further important advantage in that it eliminates certain difficulties encountered in existing water gas processes in which the fuel bed is blasted upwardly, namely, in existing water gas processes the blast air carries fly ash from the base portion of the fuel bed upwardly towards the hot coke; the ash impinging on the coke particlesV forms a glaze of non-combustible l material which slows down the rate of combustion of the coke during the blast and the steam carbon reaction during the make. By always blasting the fuel bed downwardly any ily ash in the upper portion of the -fuel bed is carried towards the base portion into a zone where, as above pointed out, the temperature. is below that at which'fusion of the ash takes place, i. e., at av l point below that at whichfthe ash tends to ux with the fuel. AccordinglyV the fly ash mixes with the ash and small clinker particles and is removed from the fuel bed by the ash removing from the generator and passed to the wash-box.

Hence operating in this manner substantial saving in oil required for carbureting the water gas is effected. Even with coke as the fuel supplied to the generator there is materially greater heat recovery in that the backrun gas is cooled in its flow through the portion of the coke bed above the point of air and steam introduction, the heat thus imparted to the coke as the coke enters the portion of the fuel bed where the air and steam is introduced thereinto being beneficially used in vcarrying out the gas making reactions.

'16 bed downwardly with an oxygen containing gas whereby the temperature of the' fuel bed gradually decreases from the point `where the oxygen containing gas is introduced in a direction towards the base of the fuel bed, the temperature at the base of the fuel bed being below the point at which substantial fusion of the ash constituents of the fuel bed takes place to form large clinker masses, burning the resultant blast gases in the heat regenerator chamber, (2) discontinuing the aforesaid blasting step and passing steam through the heat regenerator chamber and then passing the resultant superheated steam up through the fuel bed and withdrawing the resultant water gas directly from the generator, (3) discontinuing the aforesaid water gas making step and thereafter passing steam down through the fuel bed and carbureting the resultant water gas in said heat regenerator chamber and (4) mixing the resultant carbureted water gas with the gas produced in step 2 of the process.

3. A process as defined in claim 2, n which the ashI is removed substantially continuously fromfthe base of the fuel bed.v

4. A process as defined in claim 2 in which in y each cycle of steps, step 2 precedes step 3 and v isthe rfirst gas making run following the blasting The employment of a deep bed of fuel has the as hereinabove described the tar produced in the process maybe benecially utilized to make gas and at,.t he same time the fuel bed isy conditioned `so as to eliminate channelling of gas along the side walls with consequent more uniform ow of steam and'air through the active portions of th fuel bed. l f' `Si`nce changes maybe made without departing Afrom the scope of the invention, it is intended that the above description should be interpreted inan illustrative and not in a limiting sense.

What is claimed is:

" 1. In a process of making carbureted water gas in a set comprising a generator containing a bed of fuel andheat regenerator chamber which process comprises always'blasting the fuel bed downwardly with any oxygen rcontaining gas, burning the resultantv blast gases in the -heat regenerator chamber to heat this chamber, passing steam through the heat regenerator'chamber and thence tip-through the fuel bed and withdrawing the restep.

5. In a process of making water gas in a set comprising agenerator containinga bed of fuel and a heat regenerator chamber, which process comprises always blasting the fuel bed downwardly with an oxygen containing gas whereby the temperature of the fuel bed gradually decreases from the point where the oxygen containing gas is introduced in a direction towards the base of the fuel bed, burning the resultant blast gases inthe heat regenerator chamber to heat this chamber, discontinuing the aforesaid blasting step, passing steam through the heat regenerator to superheat the steam, then passing the superheated steam up through the fuel bed vand withdrawing the resultant water gas directly from the' generator, discontinuing the aforesaid water gas making step and passing steam downwardly through the fuel bed and withdrawing the resultant water gas from the base of the generator.

6. In Ia process ofmaking water gas in a vset taining gas is introduced in a direction towardsv the base of the fuel bed, the' temperature at the base ofthe fuel bed being below the point at which substantm fusion of' the ash constituents` takes lplace toform `large 4clinker masses, burnl ing the resultant blast gases in the heat regensultant water gas directly from the generator and passing steam down throughA the fuel bed and carbureting the resultant Water gas in said heat regeneratorchamber. 4

2. In a process of making carbureted water gas erator chamber to heat it, discontinuing the aforesaid blasting step, passing steam through the heaty regenerator chamber to superheat the steam and passingv the resultant superheated steam upwardly `through the fuel bedand withdrawing the resultant water gas directly from the generator,` discontinuing the aforesaid` Water gas making. step and passing steam .down

through the fuel bed, passing the resultant water gas through the heat regenerator and. substantially` continuously removing ash from the base in a set comprising a generator containing a bedA of fuel `and a heat regenerator chamber which process comprisesl (1) always blastingthe Vfuel of thefuel-bed.

7. A water gas making Iprocess as defined in claim, in which in each cycle of steps. theowv of steam up through the fuel bed precedes 4the flow or steam downthrough the fuel bed, and the ow of steaml up through the .f-uel bed is the first gas making run following the blasting step. d

8. A process of making `carbureted water gas in a set comprising a single generator containing a bed of fuel, a single carburetor and a single superheater connected in series with the base of the generator communicating with the base of the carburetor and the top of the carburetor communicating with the top of .the superheater. which process 'comprises always blasting the fuel bed downwardly' with an oxygen containing gas whereby the temperature of the fuel bed gradually decreases in a direction from the point of introduction of the oxygen containing gas into the fuel beds towards the base of the fuel bed,

`,burning the resultant blast gases as they flow up through the carburetoryand down through the superheater, discontilfuing the aforesaid blasting step, passing steam up through the superheater, down through the carburetor and into the base of the fuel bed in the generator and withdrawing the resultant water gas from the top of the generator, discontinuing the aforesaid gas making run, passing steam into the generator down through the fuel bed, passing the resultant water gas up through the carburetor, in-4 troducing a carbureting medium into the carburetor in a direction countercurrent to the flow of water gas therethrough and passing the resultant carbureted water gas down through the superheater. v y

9. A process as4 defined in claim 8, in which in each cycle of steps the carbureted water gas making step follows the gas making step involving the flow `of steam up through the fuel bed and the step involving the flow of steam up through the fuel bed is the first gas making run immediately following .the blasting step.

10. 'A process as dened in claim 8, in which at the termination of the blasting step the temperature of the base of the fuel bed is below the point at which substantial fusion of the ash constituents take place to form large clinker masses and ash is substantially continuously removed from the lbase of the fuel bed.

,y 11. In a process of makingcarbureted water gas in a set -comprising a generator containing a bed of fuel. a ycarburetor and superheater connected in series with the base of the generator communicating with4 the base of the carburetor and the top of the Icarburetor communicating with the top of the superheater and having gas off-takes leading directly from the base of the superheater and the top of the generator respectively to a wash-box, which process comprises alwaysQ blasting the fuel bed downwardly with air whereby the temperature of the fuel bed gradually decreases in a direction from the point of air introduction towards the ba-se of the fuel bed, the temperature of the base of the fuel bed at the termination of :the blasting step being below the point at which substantial fusion of the ash constituents takes place to form large clinker masses, flowing the blast gases upwardly through the carburetor and downwardly through the superheater while burning them by ythe admission of secondary air -to support ycombustion of the blast gases, discontinuing the aforesaid blasting step,'thereafter passing steam upwardly through the superheater, downwardly through the carburetor and into the base of the fuel bed in the generator, withdrawing the resultant wa- 18 ter gas from the top of the generator and passing it directly tothe wash-box, continuing the aforesaid water gas making run until from 60% to of the total steam introduced in each cycle of steps to make gas has been passed through the fuel bed, thereafter discontinuing the aforesaid water gas making run,`then intro` ducing the remainder of the steam to make gas during each cycle of steps into the top portion of Ithe fuel bed and passing it downwardly therethrough, passing the reusltant water gas from the genera-tor up through the carburetor while introducing oil intothe water gas stream in a direction countercurrent to the flow of water gas through said carburetor, passing theresultant carbureted water gas downwardly through the `superheater and thence to the washbox, and continuously removing ash from the base portion of the fuel bed.

of the coal bed and always passing this gas downy wardly through the coal bed whereby the temperature of the coal bed gradually decreases from the point of oxygen gas introduction in a direction toward the base of the coal bed, burning the resultant blast gases in the heat regenerator chamber, thereafter discontinuing the` aforesaid blasting step, passing steam through the heat regenerator to superheat thesteam, then passing the resultant superheated steam up through the coal bed, passing the water gas thus formed through the top portion of the coal bed whereby the water gas removes volatiles from the portion of the coal bed above the point at which the oxygen containing gas is introduced thereinto and withdrawing the resultant mixture of water gas and volatiles from the generator.

gas in a set comprising a generator containing a bed of coal and carburetor and superheaterv connected in series with the generator which process comprises introducing all of the oxygen containing gas employed in blasting the fuel bed at an intermediate point between the top and bottomI of the coal bed and always passing this gas downwardly through the coal bed whereby the temperature of tthe coal bed gradually decreases from the point of oxygen gas introduction in a direction towards the base of the coal bed, burning the resultant gases in the carburetor and superheater, continuing -the aforesaid blasting step until the temperature of the coal bed is adequate to carry out the water gas reaction, thereafter discontinuing the aforesaid step, passing steamthrough the superheater and carburetor to superheat the steam. then passing the resultant superheated steam, up through the coal bed, passing the water gas thus formed through the top portion of the coal bed wherebythe water gas removes volatiles from the portion of the coal bed above the point at which the oxygen containing gas is introduced thereinto, withdrawing the resultant mixture of 'water'gas and volatiles from the generator,- discontinuing the aforesaid gas making step and introducing steam at said intermediate point, passing the steam downwardly through the coal bed, withdrawing the resultant water gas from the generator, passing it through the carburetor while adding oil to the carburetor downwardly through the coal bed whereby the temperature of the coal bed gradually decreases from the point of air introduction in the direction towards the ,base of the coal bed, passing the resultant blast gases upwardly through the carburetor and downwardly through the superheater while burning them therein, continuing the aforesaid blasting step until the temperature of the coal bed is brought to a temperature suitable for carrying out the water gas reaction, (2) thereafter discontinuing the aforesaid blasting step. passing steam up through the superheater down through the carburetor and into the coal bed in the generator, passing the resultant water gas through the top portion of the coal bed whereby the water gas removes volatiles from the portion of the coal bed above the point at which the air is introduced thereinto, withdrawing the resultant mixture of water` gas and volatiles from the generator, (3) thereafter"V introducing steam into the' co'al bed at the said intermediate point,

passing the resultant steam downwardly through the coal bed passing the resultant water gas up through the carburetor while introducing oil into the carburetor in a direction countercurrent to the iiow of water gas, passing the resulting carbureted water gas up through the superheater and withdrawing the carbureted water gas from the superheater and (4) continuously removing ash from the coal bed.

15. A process as defined in claim 4 in which from 60% to 95% of the total steam introduced in each cycle of steps to make gas is introduced 20 e into the super-heater and passed upwardly therethrough, downwardly through the carburetor and into the base of the generator -and the remainder of the steam to make" gas during each cycle of steps is introduced during the subsequent step involving the introduction of steam into the tol) portion of the coal bedv and the passage thereof downwardly therethrough.

16. A process as defined in claim 11 in which bituminous coal is used as the fuel forming the fuel bed and the air during the blasting step is introduced at a point substantially mid-way between the top and bottom of the fuel bed and passed downwardly through the fuel bed and during the step involving theflow of steam up through the fuel bed the resulting water gas is passed through the portion of the fuel bed above the point of air introduction whereby the water gas removes volatiles from the bituminous coal.

17. A process of making carbureted water gas as dened in claim 1, in which a hydrocarbon material is introduced into the sides of the top portion of the iuel bed to form carbon masses at the said side portions of theiuel bed thereby preventing the channelling of gas along the sides of said fuel bed.

GEORGE R. STEERE.

REFERENCES CITED The following references are of record in the iile of this patent:

UNTTED STATES PATENTS Y Date 

